U.S. patent application number 12/361377 was filed with the patent office on 2009-07-30 for catalyst and systems incorporating the catalyst.
This patent application is currently assigned to UChicago Argonne, LLC. Invention is credited to Steven A. Cohen, Jeffrey W. ELAM, Joseph A. Libera, Michael J. Pellin, Peter C. Stair, Gerry Zajac.
Application Number | 20090191101 12/361377 |
Document ID | / |
Family ID | 40899444 |
Filed Date | 2009-07-30 |
United States Patent
Application |
20090191101 |
Kind Code |
A1 |
ELAM; Jeffrey W. ; et
al. |
July 30, 2009 |
CATALYST AND SYSTEMS INCORPORATING THE CATALYST
Abstract
A catalyst includes a carrier body and a catalytic portion
carried by the carrier body. The catalytic portion includes a
plurality of distinct layers of catalytic material, which layers
may be deposited through atomic layer deposition techniques. The
catalyst may have a selectivity for the conversion of alkanes to
alkenes of over 50%. The catalyst may be incorporated in a reactor
such as a fluidized bed reactor or a single pass reactor.
Inventors: |
ELAM; Jeffrey W.; (Elmhurst,
IL) ; Pellin; Michael J.; (Naperville, IL) ;
Libera; Joseph A.; (Clarendon Hills, IL) ; Stair;
Peter C.; (Northbrook, IL) ; Zajac; Gerry;
(Warrenville, IL) ; Cohen; Steven A.; (Naperville,
IL) |
Correspondence
Address: |
FOLEY & LARDNER LLP
321 NORTH CLARK STREET, SUITE 2800
CHICAGO
IL
60654-5313
US
|
Assignee: |
UChicago Argonne, LLC
|
Family ID: |
40899444 |
Appl. No.: |
12/361377 |
Filed: |
January 28, 2009 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61062963 |
Jan 29, 2008 |
|
|
|
Current U.S.
Class: |
422/139 ;
422/129; 502/305; 502/312; 502/353 |
Current CPC
Class: |
B01J 23/002 20130101;
B01J 35/065 20130101; B01J 35/1061 20130101; B01J 35/1019 20130101;
B01J 37/0238 20130101; B01J 23/30 20130101; B01J 35/023 20130101;
B01J 2523/00 20130101; C23C 16/45525 20130101; C23C 16/405
20130101; B01J 8/1836 20130101; B01J 35/1014 20130101; B01J 37/0244
20130101; B01J 2523/00 20130101; B01J 2523/55 20130101; B01J
2523/56 20130101; B01J 2523/69 20130101 |
Class at
Publication: |
422/139 ;
502/312; 502/353; 502/305; 422/129 |
International
Class: |
B01J 8/18 20060101
B01J008/18; B01J 23/22 20060101 B01J023/22; B01J 23/20 20060101
B01J023/20; B01J 23/30 20060101 B01J023/30; B01J 19/24 20060101
B01J019/24 |
Goverment Interests
STATEMENT OF GOVERNMENT INTEREST
[0002] The United States Government has certain rights in this
invention pursuant to Contract No. W-31-109-ENG-38 between the
United States Government and The University of Chicago and/or
pursuant to Contract No. DE-AC02-06CH11357 between the United
States Government and UChicago Argonne, LLC representing Argonne
National Laboratory.
Claims
1. A catalyst comprising: a carrier body; and a catalytic portion
carried by the carrier body, the catalytic portion comprising a
plurality of distinct layers of a catalytic material, each of the
plurality of distinct layers of the catalytic material including a
transition metal oxide and having an average thickness of between
about 0.01 nm and about 500 nm, wherein the plurality of distinct
layers of catalytic material comprise a plurality of different
transition metal oxides, and wherein the catalyst is configured to
catalyze at least one of a dehydrogenation reaction and an
ammoxidation reaction.
2. The catalyst of claim 1, wherein the carrier body is porous, and
wherein the catalytic portion is disposed on a plurality of pore
surfaces.
3. The catalyst of claim 2, wherein the pores of the carrier body
have a mean pore size that is between about 0.1 nm and about 1
.mu.m.
4. The catalyst of claim 3, wherein the carrier body consists
essentially of a ceramic material having a surface area of at least
about 1 m.sup.2/g.
5. The catalyst of claim 1, wherein at least one of the plurality
of different transition metal oxides is selected from the group
consisting of: V.sub.2O.sub.5, WO.sub.3, MoO.sub.3, NbO.sub.2,
TiO.sub.2, Al.sub.2O.sub.3, MgO, and ZrO.sub.2.
6. The catalyst of claim 5, wherein the plurality of distinct
layers include at least three different transition metal
oxides.
7. The catalyst of claim 1, wherein at least a first layer of the
plurality of layers of catalytic material comprises a vanadium
oxide based catalytic material, and wherein at least a second layer
of the plurality of layers of catalytic material comprises a
niobium oxide based catalytic material.
8. The catalyst of claim 6, wherein at least a third layer of the
plurality of layers of catalytic material comprises a tungsten
oxide based catalytic material.
9. The catalyst of claim 6, wherein the catalyst is substantially
characterized by an oxidative dehydrogenation of propane to
propylene with a selectivity to propylene of at least about 50
percent and a conversion rate of at least about 10 percent.
10. The catalyst of claim 1, wherein the average thickness of each
of the plurality of distinct layers of catalytic material is
between about 1 nm and about 100 nm.
11. The catalyst of claim 1, wherein the catalytic portion
substantially conforms to a shape of the carrier body.
12. A method for forming a catalyst comprising: providing a carrier
body; depositing a catalytic material on the carrier body
comprising a plurality of transition metal oxides; wherein
depositing a catalytic material on the carrier body comprises
depositing a plurality of layers of the catalytic material, on the
carrier body one layer at a time, wherein at least one layer of the
plurality of layers comprises a first transition metal oxide and at
least another layer comprises a second transition metal oxide, and
wherein the catalyst is configured to catalyze at least one of a
dehydrogenation reaction and an ammoxidation reaction.
13. The method of claim 12, wherein depositing one layer of the
catalytic material comprises providing a metal-based precursor to
the carrier body, and oxidizing the metal-based precursor to form
the catalytic material.
14. The method of claim 13, wherein providing a metal-based
precursor to the carrier body comprises providing the metal-based
precursor to a carrier body that comprises at least one layer of
catalytic material that has been deposited on the carrier body.
15. The method of claim 13, wherein the first and second transition
metal oxides are selected from the group consisting of:
V.sub.2O.sub.5, WO.sub.3, MoO.sub.3, NbO.sub.2, TiO.sub.2,
Al.sub.2O.sub.3, MgO, and ZrO.sub.2.
16. The method of claim 12, wherein depositing one layer of the
catalytic material comprises wet impregnation.
17. A reactor comprising: a reactor tank comprising an inlet port
configured to receive reactants and an outlet port configured to
allow reacted products to leave the reactor tank; a reactant source
configured to provide a source of short chain alkane reactants to
the reactor; and a catalyst disposed within the reactor, the
catalyst comprising: a carrier body; and a catalytic portion
carried by the carrier body, the catalytic portion including a
plurality of distinct layers of a catalytic material, each of the
plurality of distinct layers of the catalytic material including a
transition metal oxide, at least one of the plurality of layers
including a first transition metal oxide and at least another of
the plurality of layers including a second transition metal oxide,
wherein the catalyst is configured to catalyze a conversion of an
alkane reactant to an alkene product, wherein the catalyst has a
selectivity of at least about 45 percent for the conversion of the
alkane reactant to the alkene product.
18. The reactor of claim 17, wherein the reactor is configured to
fluidize the catalyst in the reactor.
19. The reactor of claim 17, wherein the carrier body comprises a
plurality porous particles having a mean pore size of at least
about 0.1 nm and a surface area of at least about 1 m.sup.2/g.
20. The reactor of claim 17, wherein the transition metal oxides
are selected from the group consisting of: V.sub.2O.sub.5,
WO.sub.3, MoO.sub.3, NbO.sub.2, TiO.sub.2, Al.sub.2O.sub.3, MgO,
and ZrO.sub.2.
Description
CROSS REFERENCE TO RELATED PATENT APPLICATIONS
[0001] The present application claims priority to U.S. Provisional
Patent Application No. 61/062,963, filed Jan. 29, 2008 incorporated
herein by reference in its entirety.
FIELD OF THE INVENTION
[0003] This application generally relates to catalysts, methods of
forming the catalysts, and reactor systems incorporating the
catalysts.
BACKGROUND OF THE INVENTION
[0004] This section is intended to provide a background or context
to the invention that is, inter alia, recited in the claims. The
description herein may include concepts that could be pursued, but
are not necessarily ones that have been previously conceived or
pursued. Therefore, unless otherwise indicated herein, what is
described in this section is not prior art to the description and
claims in this application and is not admitted to be prior art by
inclusion in this section.
[0005] Oxidative dehydrogenation (ODH) catalysis is a current
technology used for industrial chemical synthesis with a potential
for improved feed stock efficiencies, environmental impact, and
energy savings. In particular, the first step of oxidative
dehydrogenation of short-chain alkanes (ethane, propane, and
butane) is a process which, in its current form, tends to have less
than ideal energy consumption and specific conversion.
[0006] Given that short chain alkenes represent a primary feedstock
for the large scale production of a wide range of industrial
materials, this step (and the oxidative dehydrogenation process in
general) has a particular interest for development of new catalytic
materials.
SUMMARY OF THE INVENTION
[0007] A catalyst includes a carrier body and a catalytic portion
carried by the carrier body. The catalytic portion includes a
plurality of distinct layers of catalytic material, which layers
may be formed through atomic layer deposition techniques. Exemplary
catalytic materials include catalysts comprising layers of
transition metal oxides. The transition metal oxides could include
one or more of vanadium oxide, niobium oxide, molybdenum oxide,
tungsten oxide, titanium oxide, and zirconium oxide. The catalytic
material may also (or alternatively) include one or more other
metal oxide materials such as magnesium oxide and aluminum
oxide.
[0008] The catalyst may be used to catalyze an oxidative
dehydrogenation reaction, such as the conversion of alkanes (e.g.,
short-chain alkanes) to alkenes. The reaction using the catalyst
may have a selectivity for the conversion of alkanes to alkenes of
over 35%.
[0009] The catalyst could additionally (or alternatively) be used
in an ammoxidation reaction, such as the conversion of alkanes
(e.g., short-chain alkanes) to nitriles.
[0010] The catalyst may be incorporated in a reactor such as a
fluidized bed reactor or a single pass reactor.
[0011] Various aspects of the invention are described hereinafter;
and these and other objects of improvements are described in detail
hereinafter, including the drawings described in the following
section.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a cross section of a portion of an exemplary
catalyst according to some embodiments;
[0013] FIG. 2 is a process diagram for making catalysts according
to some embodiments;
[0014] FIGS. 3A and 3B illustrate a layer-by-layer process of
forming a multi-layer catalyst according to one exemplary
embodiment;
[0015] FIG. 4 is an illustration of a porous carrier body membrane
according to one exemplary embodiment;
[0016] FIG. 5 is an illustration of a porous carrier body particle
according to one exemplary embodiment;
[0017] FIG. 6 is a diagram of fluidized bed reactor incorporating
catalysts according to one exemplary embodiment;
[0018] FIG. 7 is a diagram of a pass-through reactor according to
one exemplary embodiment;
[0019] FIG. 8 is a chart illustrating the efficiency with which
some exemplary catalysts convert propane to propene;
[0020] FIG. 9 is a Raman spectroscopy plot illustrating the Raman
shift in an exemplary catalyst;
[0021] FIGS. 10A-10C are charts illustrating amounts of exemplary
catalysts loaded on to a carrier body versus time exposed to the
reaction conditions;
[0022] FIG. 11 is a diagram showing that a catalyst includes a
Vanadium component, a Niobium component, and a Tungsten
component;
[0023] FIG. 12 is a chart illustrating the efficiency with which
some exemplary catalysts convert propane to propene as well as data
for controls;
[0024] FIG. 13 is a chart illustrating the efficiency with which
some exemplary catalysts convert propane to propene; and
[0025] FIGS. 14A and 14B illustrate the pore size distribution for
two exemplary carrier bodies--Silacycle and CP8020.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0026] Referring to FIG. 1, new catalysts 10 for oxidative
dehydrogenation (ODH), ammoxidation, and/or other processes may
include a carrier body 12 which is configured to carry a catalytic
material 14. The catalytic material 14 may include two or more
layers 16-24 of catalytic material. The layers 16-24 may be
deposited using an atomic layer deposition (ALD) (discussed below),
and may be deposited monolayer-by-monolayer. See, e.g., FIGS. 3A
and 3B. The layers 16-24 may be continuous, complete layers as
depicted, or they may be discontinuous, incomplete layers comprised
of isolated particles. In some embodiments, some layers may be
deposited by ALD while other layers are deposited using some other
technique, such as wet impregnation.
[0027] The carrier body 12 may be formed as a membrane, as a
particle (e.g., a bead or powder), or as some other structure. The
carrier body 12 may be a porous body. For example, in some
embodiments the carrier body 12 may include a catalytic portion 26
(a portion of carrier body 12 on which the catalytic material 14 is
carried) having a surface area, incrementally, of at least 1
m.sup.2/g, at least 5 m.sup.2/g, at least 10 m.sup.2/g, at least 20
m.sup.2/g, at least 40 m.sup.2/g, at least 60 m.sup.2/g, at least
80 m.sup.2/g, and/or at least 100 m.sup.2/g. In some embodiments,
the carrier body 12 may have a surface area, incrementally, of up
to about 10000 m.sup.2/g, up to 5000 m.sup.2/g, up to 1000
m.sup.2/g, up to 500 m.sup.2/g, up to 250 m.sup.2/g, up to 150
m.sup.2/g, up to 120 m.sup.2/g, up to 100 m.sup.2/g, up to 80
m.sup.2/g, and/or up to 60 m.sup.2/g. In other embodiments, carrier
body 12 may have a surface area of more than 10,000 m.sup.2/g or
less than 1 m.sup.2/g.
[0028] In embodiments of the carrier body 12 that are porous, the
carrier body 12 may have a mean pore diameter, incrementally, of at
least 0.1 nm, at least 0.5 nm, at least 1 nm, at least 5 nm, at
least 10 nm, at least 15 nm, at least 20 nm, at least 25 nm, at
least 30 nm, at least 35 nm, and/or at least 40 nm. In some
embodiments of the carrier body 12 that are porous, the carrier
body 12 has a mean pore diameter, incrementally, of less than 1
.mu.m, less than 750 nm, less than 500 nm, less than 250 nm, less
than 100 nm, less than 50 nm, less than 40 nm, and/or up to about
30 nm. In other embodiments, the carrier body has a mean pore
diameter of less than 0.1 nm or more than 1 .mu.m.
[0029] If carrier body 12 is a particle, in some embodiments the
carrier body 12 may have a primary (e.g., average, median, etc.)
and/or minimum (e.g., all or substantially all particles having the
minimum) particle size (e.g., diameter, cross-sectional length,
etc.), incrementally, of at least 1 nm, at least 10 nm, at least
100 nm, at least 500 nm, at least 1 .mu.m, at least 5 .mu.m, at
least 10 .mu.m, at least 20 .mu.m, at least 35 .mu.m, at least 50
.mu.m, at least 65 .mu.m, at least 75 .mu.m, at least 90 .mu.m, at
least 100 .mu.m, at least 200 .mu.m, at least 300 .mu.m, at least
500 .mu.m, and/or at least 750 .mu.m. If carrier body 12 is a
particle, in some embodiments the carrier body 12 may have a
primary and/or maximum (e.g., all and/or substantially all of the
particles having the maximum) particle size, incrementally, of up
to about 100 mm, up to about 50 mm, up to about 10 mm, up to about
5 mm, up to about 1 mm, up to about 750 .mu.m, up to about 500
.mu.m, up to about 250 .mu.m, up to about 150 .mu.m, up to about
125 .mu.m, up to about 100 .mu.m, and/or up to about 80 .mu.m. If
carrier body 12 is a particle, in some embodiments the carrier body
12 may have a primary particle size of more than 100 mm or less
than 1 nm.
[0030] If the carrier body 12 is a membrane, in some embodiments
the carrier body may have an average thickness, incrementally, of
at least 1 .mu.m, at least 5 .mu.m, at least 10 .mu.m, at least 25
.mu.m, at least 50 .mu.m, at least 60 .mu.m, at least 80 .mu.m,
and/or at least 100 .mu.m. If the carrier body 12 is a membrane, in
some embodiments the carrier body may have an average thickness,
incrementally, of up to 5 mm, up to 1 mm, up to 500 .mu.m, up to
250 .mu.m, up to 150 .mu.m, up to 100 .mu.m, and/or up to 80 .mu.m.
If the carrier body 12 is a membrane, in other embodiments the
carrier body may have an average thickness of more than 5 mm or
less than 1 .mu.m.
[0031] The carrier body 12 may be formed from any material. In some
embodiments, the carrier body may be formed from an inorganic
and/or non-metallic material. In some of these embodiments, carrier
body 12 may include a ceramic material (e.g., may include,
incrementally, at least 50, at least 70, and/or at least 90 percent
ceramic material by volume). For example, carrier body 12 may
include one or more of a silica material, an alumina material, and
an aluminum oxide material (e.g., an anodic aluminum oxide
material). Carrier body 12 may be formed from more than one
material, such as a silica-coated alumina powder, silica coated
anodic aluminum oxide membrane, etc.
[0032] The catalytic material 14 is carried by the carrier body 12.
The catalytic material 14 may be configured to conform to the shape
of carrier body 12 (e.g., the catalytic material 14 may have
roughly the same shape as the carrier body 12 onto which the
catalytic material 14 is deposited). For example, the catalytic
material 14 may form a second porous structure over the porous
structure of a porous carrier body 12 such that the porous shape
formed by the catalytic material 14 is based on and/or similar to
(e.g., follows the shape of) the porous structure of the carrier
body 12.
[0033] The catalytic material 14 may include any catalytic
material. In some embodiments, the catalytic material 14 may be a
metal oxide material such as a transition metal oxide. For example,
the catalytic material 14 may be a Vanadium-based catalytic
material (e.g., V.sub.2O.sub.5), a Tungsten-based catalytic
material (e.g., WO.sub.3), a Molybdenum-based catalytic material
(e.g., MO.sub.3), a Niobium-based catalytic material (e.g.,
Nb.sub.2O.sub.5), a titanium-based catalytic material (TiO.sub.2),
an aluminum-based catalytic material (Al.sub.2O.sub.3), a
magnesium-based catalytic material (MgO), and/or a Zirconium-based
catalytic material (ZrO.sub.2)
[0034] The catalytic material 14, may include multiple layers
16-24. In some multi-layer embodiments, the catalytic material 14
may include at least 2 layers, at least 3 layers, at least 4
layers, at least 5 layers, at least 7 layers, at least 9 layers, at
least 11 layers, and/or at least 13 layers.
[0035] In some embodiments, one or more (e.g., a plurality, at
least half, substantially all, and/or all) of the layers 16-24 may
have an average and/or maximum thickness, incrementally, of up to
about 100 microns, 50 microns, 25 microns, 10 microns, 5 microns, 1
micron, 500 nm, 100 nm, 50 nm, 25 nm, 10 nm, 5 nm, and/or 1 nm. In
some embodiments, one or more (e.g., a plurality, at least half,
substantially all, and/or all) of the layers 16-24 may have an
average and/or maximum thickness of at least about 0.01 nm, 0.05
nm, 0.1 nm, 1 nm, 10 nm, 100 nm, and/or 500 nm. In some
embodiments, one or more of the layers 16-24 may meet one set of
dimensions listed above, while one or more other layers 16-24 may
meet a different set of dimensions listed above. Additionally,
individual layers 16-24 may or may not be continuous. In some
embodiments, one or more layers 16-24 may consist of isolated atoms
or clusters of atoms that are spaced apart from one another such
that the average thickness of the layer 16-24 is much less than the
thickness of an atom.
[0036] In some embodiments, the catalytic material 14 may have an
average and/or maximum thickness of up to about 100 microns, 50
microns, 25 microns, 15 microns, 10 microns, 5 microns, 1 micron,
500 nm, 250 nm, 100 nm, 75 nm, 50 nm, 25 nm, and/or 10 nm. In some
embodiments, catalytic material 14 has an average and/or maximum
thickness of at least about 0.1 nm, 0.5 nm, 1 nm, 5 nm, 10 nm, 25
nm, 50 nm, 100 nm, 250 nm, 500 nm, 750 nm, 1 micron, 5, microns, 10
microns, and/or 25 microns.
[0037] The multiple layers 16-24 may be formed from different
catalytic materials. For example, one layer 16 may be a
V.sub.2O.sub.5 layer, while another layer 18 may be a
Nb.sub.2O.sub.5 layer. Two or more of the multiple layers 16,22 may
be formed from the same material (e.g., V.sub.2O.sub.5) while at
least one other layer 18 (e.g., a layer between the two layers
16,22 formed from the same material) is formed from a different
material (e.g., WO.sub.3). Each of the layers 16-24 may be
essentially pure such that at least 90% and/or at least 95% of each
individual layer 16-24 is formed from a common type of material. In
some embodiments, the catalytic material 14 includes at least two,
at least three, and/or at least four layers 16-24 that are
compositionally distinct from each other.
[0038] In some embodiments, the catalyst 10 may be configured to
catalyze a dehydrogenation reaction (e.g., an oxidative
dehydrogenation reaction) and/or an ammoxidation reaction. In some
embodiments, the catalyst 10 is configured to catalyze a
dehydrogenation and/or ammoxidation reaction of an alkane;
particularly a short chain alkane (e.g., C.ltoreq.10, C.ltoreq.7,
and/or C.ltoreq.4) such as ethane, propane, and/or butane. The
catalyst 10 may have a good selectivity for conversion of an alkane
to an alkene. For example, the catalyst may have a selectivity for
conversion of an alkane to an alkene, incrementally, of at least
about 35%, at least about 40%, at least about 45%, at least about
50%, at least about 60%, at least about 70%, at least about 80%,
and/or at least about 90%. In some embodiments, the catalyst may
have any of the above listed selectivities while facilitating a
conversion rate of reactants to products, incrementally, of at
least about 5%, at least about 7%, at least about 10%, at least
about 12%, at least about 14%, at least about 16%, at least about
20%, at least about 30%, at least about 40%, at least about 50%, at
least about 75%, and/or at least about 90%.
[0039] The catalyst 10 may be formed by any number of methods. In
many exemplary embodiments, the catalyst can be formed by atomic
layer deposition (ALD). ALD utilizes alternating exposures between
precursors (e.g., in a gaseous form) and a solid surface to deposit
materials in a monolayer-by-monolayer fashion. This process can
provide uniformity of the coatings in many embodiments, including
on nanoporous substrate materials (e.g., nanoporous carrier bodies
12). In many embodiments, this process also allows good control
over the thickness and composition of the coatings.
[0040] Referring to FIGS. 1 and 2, to form a catalyst 10 by ALD,
the carrier body 12 substrate (e.g., particles, membrane, etc.) is
first exposed 210 to a chemical vapor precursor containing the
desired metal atom (e.g., trimethyl aluminum). Second, the
substrate is purged 220 with an inert gas (e.g., nitrogen) to
remove any unreacted precursor as well as gaseous reaction
byproducts. Third, the substrate is exposed 230 to a vapor of an
oxygen-containing chemical precursor such as water. Finally, the
carrier body 12 substrate is again purged 240 with inert gas.
[0041] This four-step procedure is referred to as an "ALD cycle
250." For catalysts 10 having multiple layers 16-24 of catalytic
material, the ALD cycle 250 can be repeated multiple times to
deposit a multilayer film of catalytic material 14 (e.g., metal
oxide) which may be used to precisely control the film thickness.
In some embodiments, the layers 16-24 of the catalytic material 14
may have quantized thickness (the thicknesses of the layers 16-24
are essentially integers of each other). A majority of the layers
16-24 may have quantized thicknesses, essentially all of the layers
16-24 may have quantized thicknesses, and/or all the layers 16-24
may have quantized thicknesses. Moreover, ALD cycles for different
catalytic materials (e.g., metal oxide materials such as
V.sub.2O.sub.5 and Nb.sub.2O.sub.5) can be combined in specific
sequences to deposit mixed-catalytic (e.g., metal oxide) layers
16-24 to control the atomic composition of the catalytic material
14.
[0042] If multiple ALD cycles 250 are used to deposit multiple
layers 16-24, the multiple layers may be provided in a binary
manner such that at least some (e.g., at least half) of the layers
have a different composition than the adjacent layers.
[0043] Referring to FIG. 6, a fluidized bed catalytic reactor 502
includes a solid catalyst 524 fluidized in an upper portion 540 of
a fluid 526 contained in a reactor tank 536. The tank 536 also
includes a distributor 522 which may be configured to prevent
substantially any amount of the catalyst 524 from entering a lower
portion 516 of the fluid 526.
[0044] An input source 510 (e.g., a container such as tank)
contains a material to be catalyzed that is pumped by a pump 512
under the control of a control circuit 518. The material contained
in the input source 510 may be any of a variety of materials. The
material may be a fluid (e.g., a gas)--in particular a short chain
alkane (e.g., C.ltoreq.10, C.ltoreq.7 and/or C.ltoreq.4) fluid
material such as ethane, propane, and/or butane. The input source
510 may also include one or more other materials such as a material
to promote oxidation (e.g., O.sub.2 gas) and/or an inert diluent
(e.g., N.sub.2). Of course, these additional materials (if used)
could also be provided from a separate input source (not
illustrated).
[0045] The reactant contained in the reactant source 510 is pumped
through a channel 514 into a lower portion 516 of the fluid 526.
The pumping of the reactant into the fluid 526 may serve to
maintain the catalyst 524 in a fluidized state. The reactant pumped
into fluid 526 contacts the catalyst 524, and is reacted in a
reaction catalyzed by the catalyst 524 in the fluid 526. In some
embodiments, catalyst 524 may be configured to catalyze a
dehydrogenation reaction (e.g., an oxidative dehydrogenation
reaction) and/or an ammoxidation reaction. Reacted (and also
possibly unreacted) material exits the tank 536 through an output
port 534.
[0046] The reactor 502 may be configured to maintain the same
catalyst particles in the reaction tank 536, or may be configured
to refresh the catalyst in the tank with supplemental catalyst
particles. For example, the reactor 502 may include a catalyst
source 530 configured to provide supplemental catalyst to the fluid
526 in the tank 536 through a channel 532. The catalyst amount
and/or timing of material provided by the source 530 may be
controlled by any control structure (e.g., a valve, a belt that
transports catalyst, etc.) which may be under the control of a
control circuit (e.g., control circuit 518). The reactor 502 may
also be configured such that some of the catalyst 524 that is in
the fluid 526 is removed from the tank 536. For example, the tank
536 may include a catalyst exit port 538. The fluid surface 528 may
be maintained at a level that is at least partially above the
starting edge 539 of the exit port 538 such that some of the fluid
526 and the catalyst 524 in the fluid 526 exits through the exit
port 538.
[0047] The reactor 502 may include any number of other components
configured to facilitate reaction of the reactant contained in the
reactant source 510. For example, the reactor 502 may include a
heater 520 configured to heat the tank 536 and/or the components
contained in the tank 536. The heater 520 may also be operated
under the control of the control circuit 518.
[0048] In some embodiments, the reactor 502 is configured to have,
incrementally, at least about 10 g, at least about 50 g, at least
about 100 g, at least about 250 g, at least about 500 g, at least
about 1 kg, at least about 10 kg, at least about 100 kg, at least
about 250 kg, at least about 500 kg, at least about 750 kg, at
least about 1000 kg, at least about 5000 kg, at least about 10,000
kg, and/or at least about 25,000 kg of the catalyst 524 in the
fluid 526 and/or in the entire system of the reactor 502. In other
embodiments, the reactor 502 may have less than 10 g of the
catalyst 524 in the fluid 526 and/or in the entire system of the
reactor 502.
[0049] Referring to FIG. 7, a single pass reactor 602 includes a
reactant source 610 configured to provide reactant under the
control of a control structure 612 (e.g., valve, pump, etc.) which
is controlled by a control circuit 618. Reactant enters a reaction
chamber 636 through a channel 614 connected to an inlet 615 of the
reaction chamber 638. The reactant pumped into the chamber 636
contacts the catalyst 624 (and/or catalyst 625) which is fixed to
an interior surface of the chamber 636. The reactant is reacted in
a reaction catalyzed by the catalyst 624. In some embodiments, the
catalyst 624 may be configured to catalyze a dehydrogenation
reaction (e.g., an oxidative dehydrogenation reaction) and/or an
ammoxidation reaction. Reacted (and also possibly unreacted)
material exits the chamber 636 through an output port 634. The
reactor 602 may include any of the other components of the reactor
502 of FIG. 6, such as the heater 502, the fluid 526, etc.
EXAMPLES
[0050] The following non-limiting examples are presented to
illustrate the present invention and to assist one of ordinary
skill in making and using the same. The examples are not intended
in any way to otherwise limit the scope of the invention.
Example 1
[0051] As a substrate material, we are using commercial silica gel
powder (Silicycle S10040M) with a specific surface area of 100
m.sup.2/g, a primary particle size of 75-200 microns, and a nominal
pore diameter of 30 nm.
[0052] The high surface area silica gel powder was contained in a
fixed-bed powder fixture. The bottom tray of this fixture is
constructed from 304 stainless steel with dimensions 143
mm.times.29 mm.times.3.2 mm deep. The top of the powder fixture is
comprised of a 200.times.600 mesh stainless steel wire cloth cover
with 40% open area supported by a perforated stainless steel plate.
The fine mesh cover prevents convective gas currents from
disturbing the flat powder layer at the bottom of the powder tray
while allowing efficient diffusion of reactant and product gases in
and out of the powder bed. The dimensions of the powder tray were
selected such that the thickness of a silica gel powder layer with
a mass of 1.0 g would be .about.0.5 mm or .about.8 particle
diameters while leaving .about.2.7 mm of clearance between the
powder layer and the cover. By spreading the silica gel powder into
a thin layer, we ensure that diffusion of the ALD reactant gases
between the silica gel particles is rapid.
[0053] The catalysts consist of a mixed oxide of Nb.sub.2O.sub.5,
V.sub.2O.sub.5 and WO.sub.3. Each of these oxide materials is
deposited by ALD using different precursor combinations, exposure
times, and substrate temperatures. These parameters are given in
table 1. The quantities in table 1 are applicable to coating 1-gram
quantities of the Silicycle S10040M powder substrate.
[0054] For example, the procedure for WO.sub.3 given in table 1
deposits metallic tungsten to coat the powder substrate. The
tungsten coating is formed into tungsten oxide by exposing the
tungsten-coated powder to oxygen for 250 seconds at 200.degree.
C.
TABLE-US-00001 TABLE 1 Parameters for depositing catalytic metal
oxide layers by ALD on Silicycle powder. Oxygen Metal Precursor
Substrate Precursor Oxygen/Reducing Metal or reducing Temperature
Exposure agent Exposure Oxide Metal Precursor agent (.degree. C.)
Time (s) Time (s) V.sub.2O.sub.5 Vanadium oxide Hydrogen 100 300
300 tri-isopropoxide peroxide Nb.sub.2O.sub.5 Niobium Water 200 240
120 pentethoxide WO.sub.3 Tungsten Disilane 200 250 250
hexafluoride
[0055] FIGS. 10A-C illustrate the loading of these catalysts at
different metal precursor exposure times than those listed in Table
1.
Example 2
[0056] A set of ALD catalysts were prepared varying the relative
amounts of the different metal oxides as shown in Table 2. These
catalyst samples were prepared using a silica gel carrier with
physical properties very similar to the S10040M described above.
These catalyst samples were prepared by depositing the metal oxide
layers in the order: Nb.sub.2O.sub.5, WO.sub.3, V.sub.2O.sub.5.
TABLE-US-00002 TABLE 2 ALD catalysts prepared for testing Catalyst
Sample ID V.sub.2O.sub.5 Nb.sub.2O.sub.5 WO.sub.3 Number Cycles
Cycles Cycles JL_006 3 0 0 JL_284 1 12 0 JL_285 1 12 1
Example 3
[0057] The catalysts of Example 2 were tested for the oxidative
dehydrogenation of propane to propylene. Initially the reactivities
were surveyed at three space velocities: 0.20, 0.10, and 0.05 wwh
(where wwh is in units of grams propane/gram catalyst/hour) at
temperatures between 400 and 430.degree. C.
[0058] The feed ratios were 1.0 O.sub.2/12.0 N.sub.2/1.0
propane.
[0059] Next, the catalysts were tested using the lowest space
velocity with half the nitrogen diluent (feed ratios of 1.0
O.sub.2/6.0 N.sub.2/1.0 propane) at a temperature of 430.degree. C.
The results are shown in FIG. 8.
[0060] FIG. 8 demonstrates a selectivity to propylene of .about.50%
at a conversion of .about.16% for JL.sub.--006. Upon addition of
Nb.sub.2O.sub.5 (JL.sub.--284), the propylene selectivity increases
slightly. With the addition of WO.sub.3 (JL.sub.--285) the
propylene selectivity decreases and more CO.sub.2 is formed.
Example 4
[0061] FIG. 9 illustrates a Raman spectroscopic analysis of a
catalyst formed from atomic layer deposition of a V.sub.2O.sub.5
catalyst. The analysis illustrates that atomic layer deposition
yields high dispersion at high loading.
Example 5
[0062] A fluidized bed catalytic reactor is formed as shown in FIG.
6 using a catalyst as described in Example 1. A propane tank
delivers propane mixed with oxygen and diluted with nitrogen to a
reaction chamber of the reactor. The propane is converted to
propylene in a reaction that is catalyzed by the catalyst.
Example 6
[0063] A catalyst is formed as described in Example 1. The catalyst
material of the catalyst includes only Nb.sub.2O.sub.5. The
catalyst includes 12 cycles of Nb.sub.2O.sub.5.
Example 7
[0064] A catalyst is formed as described in Example 1. The catalyst
material of the catalyst includes only WO.sub.3. The catalyst
includes 3 cycles of WO.sub.3.
Example 8
[0065] A catalyst is formed as described in Example 1. The catalyst
material of the catalyst includes alternating layers of WO.sub.3
and V.sub.2O.sub.5. The catalyst includes 3 cycles of WO.sub.3 and
1 cycle of V.sub.2O.sub.5.
Example 9
[0066] Another catalyst is formed as discussed above in Examples 1
and 2, except that an anodic aluminum oxide membrane having a
structure prepared by the schematic flow diagram as show in FIG. 4
is used as the carrier substrate.
Example 10
[0067] A pass through reactor as shown in FIG. 7 is formed using
the catalyst described in Example 9.
Example 11
[0068] A catalyst is formed as described in Example 1 except that
alumina particles are used as the support carrier. The catalyst
material of the catalyst includes alternating layers of WO.sub.3
and V.sub.2O.sub.5. The catalyst includes 3 cycles of WO.sub.3 and
1 cycle of V.sub.2O.sub.5.
Example 12
[0069] A catalyst is formed as described in Example 1 except that
an anodized aluminum oxide membrane is used as the support carrier.
The catalyst material of the catalyst includes alternating layers
of WO.sub.3 and V.sub.2O.sub.5. The catalyst includes 3 cycles of
WO.sub.3 and 1 cycle of V.sub.2O.sub.5.
Example 13
[0070] A catalyst is formed as described for embodiment
JL.sub.--285 of Example 2 except that the support carrier particles
are formed from silica on alumina. The silica is applied to the
alumina by ALD.
Example 14
[0071] A catalyst is formed as described for embodiment
JL.sub.--285 of Example 2 except that an anodized aluminum oxide
membrane is used as the support carrier.
Example 15
[0072] The catalysts of Example 2 are used for the ammoxidation of
propane to acrylonitrile.
Example 16
[0073] Additional exemplary catalysts are formed from catalysts and
carrier supports as shown in the following chart. Wet impregnation
involves dissolving a salt of the desired material into a solution
(e.g., ammonium metavanadate for V.sub.2O.sub.5). Immerse the
support in the solution, and evaporate the solvent. Then, calcine
(heat in air) to produce the V.sub.2O.sub.5.
TABLE-US-00003 Description Support Sample ID 3 cycles V (3% V)
CP8020 JL_ALD_006 12 cycles Nb, 1 cycle V (1% V) CP8020 JL_284 12
cycles Nb, 1 cycle V, 1 cycle W CP8020 JL_285 12 cycles Nb CP8020
JL_296 12 cycles Nb, 1% V (wet CP8020 JE_1260 impregnation) 12
cycles Nb, 3% V (wet CP8020 JE_1261 impregnation) 12 cycles Nb
Silacycle JL_314 12 cycles Nb, 1 cycle V Silacycle JL_315 12 cycles
Nb, 2 cycles V Silacycle JL_316 12 cycles Nb, 4 cycles V Silacycle
JL_317 12 cycles Nb, 2 cycle V, "1 ML" Mo Silacycle JL_320 (wet
impregnation)
[0074] FIG. 12 illustrates the efficiency with which some of these
catalysts convert propane to propene. Comparing JL.sub.--284 (ALD
V.sub.2O.sub.5) and JE.sub.--1260 (wet impregnation
V.sub.2O.sub.5), the ALD gives much higher selectivity than the
conventional wet impregnation. See FIG. 13.
[0075] All of the samples on CP8020 give higher selectivity than
the equivalent samples on Silicycle. These 2 supports are nearly
equivalent except for the pore size distribution. Silicycle S10040M
is 100 m.sup.2/g, 75-200 micron primary particles, and 30 nm
average pore diameter and CP8020 is 80 m.sup.2/g, about 100 micron
primary particles, and about 30 nm average pore diameter. FIG. 14A
illustrates the pore size distribution for Silacycle and FIG. 14B
illustrates the pore size distribution for CP8020. Note that CP8020
has a bimodal pore size distribution.
[0076] The foregoing description of embodiments of the present
invention has been presented for purposes of illustration and
description. It is not intended to be exhaustive or to limit the
present invention to the precise form disclosed, and modifications
and variations are possible in light of the above teachings or may
be acquired from practice of the present invention. The embodiments
were chosen and described in order to explain the principles of the
present invention and its practical application to enable one
skilled in the art to utilize the present invention in various
embodiments, and with various modifications, as are suited to the
particular use contemplated.
* * * * *